head SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 9B-29 Lighting Systems:
Height Sensor Removal and Installation (If
Equipped)
S6RW0D9206027
Removal
CAUTION!
• Do not remove bracket (4) and link (3) from
height sensor (2). Removal will spoil its
original function. If faulty condition is
found, replace it with new one in a set.
• If height sensor was dropped from a height
of 30 cm (0.9 ft) or more, replace it with
new one.

1) Disconnect negative (–) cable at battery.
2) Disconnect height sensor connector (1) from height
sensor (2).
3) Remove front and rear height sensor (2) with its
bracket (4) from suspension frame (6) or rear floor
center cross member (7) and lower arm (5).Installation
For installation, reverse removal procedure noting the
following.
• Check that bracket and link of height sensor are not
deformed.
• Tighten height sensor bolts and nuts to specified
torque.
Tightening torque
Height sensor bolt (a): 5.5 N·m (0.6 kgf-m, 4.0 lb-ft)
Height sensor nut (b): 13 N·m (1.3 kgf-m, 9.5 lb-ft)
• Connect connector securely.
• After installation, initialize headlight auto leveling
system referring to “Initialization of Headlight Auto
Leveling System”.
[A]: Front [B]: Rear
12
7
[B] [A]
4
3
2
6
3
5
5
1
4
4
4
I6RW0C920022-01
[A]: Front [B]: Rear
[B] [A]
(b)
(a)
(a)
(a)
I6RW0C920023-01

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-30
Height Sensor and Its Circuit Inspection (If
Equipped)
S6RW0D9206028
1) Remove front or rear height sensor from vehicle
referring to “Height Sensor Removal and Installation
(If Equipped)”.
2) Connect connector to height sensor.
3) Vary position of height sensor link (1) and measure
voltage between terminals of headlight leveling
control module (4) as described below.
• For front height sensor
Between “G14-20” and “G14-22” terminals of
headlight leveling control module.
• For rear height sensor
Between “G14-19” and “G14-21” terminals of
headlight leveling control module.
If check result is not as specified, perform
inspections of power supply, ground and signal
circuits of front or rear height sensor which is
described under “Inspection of Headlight Leveling
Control Module and Its Circuit (Headlight Auto
Leveling System)”. If circuits are OK, replace
height sensor.
Height sensor output voltage
Full bound position (2): about 0.5 V
Full rebound position (3): about 4.5 V
Headlight Leveling Control Module Removal
and Installation (If Equipped)
S6RW0D9206029
Removal
1) Disconnect negative (–) cable at battery.
2) Remove glove box.
3) Disconnect connector (1) from headlight leveling
control module (2).
4) Remove headlight leveling control module with its
bracket from steering support member (3).
Installation
For installation, reverse removal procedure noting the
following.
• Connect connector securely.
• After replacing headlight leveling control module with
new one, initialize headlight auto leveling system
referring to “Initialization of Headlight Auto Leveling
System”.
Initialization of Headlight Auto Leveling SystemS6RW0D9206030
Initialization of the headlight auto leveling system is to
make the headlight leveling control module learn signals
which are fed from the height sensors when the vehicle
is at the standard height. Standard height means the
height of the vehicle with a driver but without load in it.
Initialization of the headlight auto leveling system is
required when any of the following works has been
performed.
• Replacement of headlight leveling control module
• Removal of front and/or rear height sensor link from
lower arm
• Removal of front and/or rear height sensor from
suspension frame
• Replacement of front and/or rear height sensor
[A]: Front [B]: Rear
[A] [B]
4
G14
10 11 12 13 16 17 18 19 2031 5 6 9
21 22 23 24
V
2
3 1
2
3
1
I6RW0C920024-01
23 1
I6RW0C920025-01

Downloaded from www.Manualslib.com manuals search engine 9B-31 Lighting Systems:
Without initialization of the headlight auto leveling
system, it is not possible to obtain its proper function.
Also, if the headlight auto leveling system is not
initialized after replacing the headlight leveling control
module, the headlight leveling warning light in the
combination meter flashes.
1) Observe the following instructions.
• Park vehicle on level ground.
• Adjust air pressure of all tires to the specified
value respectively.
• Bounce vehicle body up and down by hand to
stabilize suspension.
2) Turn ignition switch to ON position.
3) Perform “Headlight Leveling Warning Light Check”.
4) Connect service wire (2) to terminals of diagnosis
connector (1).
5) Perform Steps a) through b) described blow within
20 seconds after Step 4).
a) Turn lighting switch (3) to “HEAD” position and
then turn lighting switch to OFF position.
b) Repeat Step a) 2 times.
6) Confirm that headlight leveling warning light flashes
3 times and turns off, which indicates that system
initialization was completed properly. If it does not
turn off after flashing 3 times, it means initialization
was not successful. In such case, turn off ignition
switch and perform Steps 1) to 6) again.Auto-On Headlight Sensor Inspection (If
Equipped)
S6RW0D9206031
1) Disconnect negative (–) cable at battery.
2) Remove auto-on headlight sensor (1) located on the
passenger side of the dashboard (2). Be careful not
to damage the sensor (1) and dashboard by using
rag (3).
3) Measure voltage between white wire terminal and
black wire terminal at the following condition.
If measured voltage is out of specification, replace
sensor.
Auto-on headlight sensor voltage specifications
Cover the sensor lens with hand: 0.4 V
Light the sensor lens with incandescent lamp
100 W: 3 – 4.5 V3
1
2
I6RW0C920021-01
1
I6RW0C920009-01
2
1
3I5JB0A920038-01
I5JB0A920039-01

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-32
Illumination Cancel Switch Inspection (If
Equipped)
S6RW0D9206022
Check for continuity between terminals at each switch
position.
If check result is not as specified, replace switch.
Tail Light Relay, Headlight Relay, Front Fog
Light Relay Inspection (If Equipped)
S6RW0D9206032
1) Remove tail light relay (1), headlight relay and/or
front fog light relay (2).
2) Check that there is no continuity between terminal
“3” and “4”. If there is continuity, replace relay.
3) Connect battery positive (+) terminal to terminal “2”
of relay.
4) Connect battery negative (–) terminal to terminal “A”
of relay.
5) Check continuity between terminal “3” and “4”. If
there is no continuity when relay is connected to the
battery, replace relay.
1
2
3
Switch PositionTerminal
ON (PUSH IN)123
OFF
I5RW0A920015-01
8
[B] [A]
3
4
1
5 62
2
I6RW0C920027-02
[A]: Junction block with BCM type (other than discharge headlight model)
[B]: Junction block with BCM type (discharge headlight model)
[C]: Junction block without BCM type
3. Headlight low beam relay (left side)
4. Headlight low beam relay (right side)
5. Headlight high beam relay (left side)
6. Headlight high beam relay (right side)
7. Junction block
8. Battery
7
7
5 6
1
8
3
42 [C]
I6RW0C920028-01
“4” “2”“1”“3”
I4RS0A920022-01

Downloaded from www.Manualslib.com manuals search engine Instrumentation / Driver Info. / Horn: 9C-1
Body, Cab and Accessories
Instrumentation / Driver Info. / Horn
Precautions
Precautions in Diagnosing Troubles for Combination MeterS6RW0D9300001
Combination meter uses signals (information) from each control module by CAN communication to control
speedometer, tachometer, fuel meter, engine coolant temp meter, warning light and indicator light (other than air bag
warning light, EPS warning light, headlight leveling warning light (if equipped), rear fog light indicator light (if
equipped), high beam indicator light and turn signal indicator light). Therefor, check that no DTC is detected in each
module before performing combination meter symptom diagnosis. If any DTC is detected, correct trouble indicated by
that DTC troubleshooting first.
General Description
CAN Communication System DescriptionS6RW0D9301001
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description.
Combination meter communicates control data with each control module as follows.
Combination Meter Transmission Data
BCM
Combination
meterDATA
TransmitCombination meter spec signal
I5RW0A930001-02

Downloaded from www.Manualslib.com manuals search engine 9C-4 Instrumentation / Driver Info. / Horn:
Schematic and Routing Diagram
Combination Meter Circuit DiagramS6RW0D9302001
7
6
5
4G241-99
G241-5
1
2
11
G241-1323
G241-31
G241-263
G241-16
G241-2212
G241-2513
G241-13
8 17
1514
20
G241-32
G241-69
16
18
19
G241-2121
G241-7 G241-10 10
10
G241-1922
I6RW0D930002-01
1. DOME fuse 9. 4WD control module (if equipped) 17. CAN driver
2. METER fuse 10. CAN junction connector 18. Stepper motor and LED output driver
3. Combination switch 11. SDM 19. A/T shift position indicator (“P”, “R”, “N”, “D”, “3”, “2” and “L”)
4. Tachometer 12. Combination switch (high beam) 20. Combination meter
5. Speedometer 13. P/S control module 21. Combination switch (rear fog light)
6. Fuel meter 14. CPU 22. Headlight leveling control module (if equipped)
7. ECT meter 15. Power supply 23. Illumination cancel switch (if equipped)
8. ODO-TRIP 16. Interface circuit

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Terminal arrangement of coupler viewed from terminal side
NOTE
Molded numbers (1) have no relation to the terminal numbers.

Component Location
Audio System Component LocationS6RW0D9303001
Terminal Circuit Terminal Circuit
G241-1 To turn signal light switch (turn R) G241-17 —
G241-2 — G241-18 —
G241-3 — G241-19To headlight leveling control module (if
equipped)
G241-4 — G241-20 —
G241-5 To SDM (air bag warning light control signal) G241-21 To rear fog light switch (if equipped)
G241-6 CAN communication line (Active High Signal) G241-22 To lighting switch (high beam)
G241-7 CAN communication line (Active High Signal) G241-23 —
G241-8 — G241-24 —
G241-9 CAN communication line (Active Low Signal) G241-25To P/S control module (EPS warning light
control signal)
G241-10 CAN communication line (Active Low Signal) G241-26 To turn signal light switch (turn L)
G241-11 — G241-27 —
G241-12 — G241-28 —
G241-13 To illumination cancel switch (if equipped) G241-29 —
G241-14 — G241-30 —
G241-15 — G241-31 To METER fuse
G241-16 GND G241-32 To DOME fuse
G241-1G241-16
G241-32 G241-17
11I7RW01930004-01
3
2
3
2
1
4
8
8
9
96
5
(a)
7
I6RW0D930003-02
1. Radio or navigation
assembly4. Antenna feeder 7. GPS antenna (if equipped) : 5.0 N⋅m (0.5 kgf-m, 4.0 lb-ft)
2. Front speaker 5. Antenna 8. Front tweeter speaker (if equipped)
3. Rear speaker 6. Antenna base 9. Rear tweeter speaker (if equipped)

Downloaded from www.Manualslib.com manuals search engine Instrumentation / Driver Info. / Horn: 9C-9
Charge Warning Light Symptom DiagnosisS6RW0D9304010
Main Beam (High Beam) Indicator Symptom DiagnosisS6RW0D9304011
Warning Buzzer Circuit Symptom DiagnosisS6RW0D9304012
NOTE
• Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or
output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of
SUZUKI Scan Tool” under “Scan Tool Data in Section 10B”.
• Check each part in the order from the top of the following list.

Condition Possible cause Correction / Reference Item
Charge warning light
does not come ONCircuit fuse blownReplace fuse and check for short circuit.
Wiring or grounding faultyRepair circuit.
Combination meter faultyReplace combination meter.
BCM faulty Replace after making sure that none of above
parts is faulty.
Charge warning light stay
ONCharging system faultyCheck charging system.
Wiring or grounding faultyRepair circuit.
Combination meter faultyReplace combination meter.
BCM faulty Replace after making sure that none of above
parts is faulty.
Condition Possible cause Correction / Reference Item
Main beam (high beam)
indicator does not come
ONCircuit fuse blownReplace fuse and check for short circuit.
Combination switch faultyCheck combination switch referring to
“Headlight Switch (in Lighting Switch)
Inspection in Section 9B”.
Wiring or grounding faultyRepair circuit.
Combination meter faultyReplace combination meter.
Main beam (high beam)
indicator stay ONCombination switch faultyCheck combination switch referring to
“Headlight Switch (in Lighting Switch)
Inspection in Section 9B”.
Wiring or grounding faultyRepair circuit.
Combination meter faultyReplace combination meter.
Condition Possible cause Correction / Reference Item
Warning buzzer shows no
soundingCircuit fuse blownReplace fuse and check for short circuit.
Driver side door switch faultyCheck driver side door switch referring to
“Door Switch (Front / Rear Door) Inspection”.
Lighting switch faultyCheck lighting switch referring to “Headlight
Switch (in Lighting Switch) Inspection in
Section 9B”.
Key reminder switch faultyCheck key reminder switch referring to
“Ignition Switch Inspection”.
Seat belt switch faultyCheck seat belt switch referring to “Front Seat
Belt Inspection in Section 8A”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.

Downloaded from www.Manualslib.com manuals search engine Instrumentation / Driver Info. / Horn: 9C-21
Antenna Base Removal and InstallationS6RW0D9306023
Removal
1) Remove head lining referring to “Head Lining
Removal and Installation in Section 9H”.
2) Remove antenna (1) from antenna base (2).
3) Disconnect antenna feeder from antenna base (2).
4) Remove antenna base (2) from vehicle.
Installation
Reverse removal procedure noting the following.
• Tighten antenna base mounting bolt to specified
torque.
Tightening torque
Antenna base mounting bolt (a): 5.0 N·m (0.5 kgf-
m, 4.0 lb-ft)
• Install head lining referring to “Head Lining Removal
and Installation in Section 9H”.
Remote Audio Control Switch Removal and
Installation (If Equipped)
S6RW0D9306024
Remove
1) Remove steering wheel referring to “Steering Wheel
Removal and Installation in Section 6B”.
2) Remove steering wheel cover (1) from steering
wheel.
3) Remove remote audio control switch (1) from
steering wheel.
Installation
Reverse removal procedure noting the following.
• Install steering wheel referring to “Steering Wheel
Removal and Installation in Section 6B”.
(a)1
2
I7RW01930012-01
2. Screw
2. Screw
2
1
I5RW0A930025-02
1
2
I5RW0A930026-02

Downloaded from www.Manualslib.com manuals search engine Wipers / Washers: 9D-3
Washer Tank and Washer Pump Removal and
Installation
S6RW0D9406002
Removal
1) Disconnect negative (–) cable at battery.
2) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
3) Disconnect washer pump lead wire couplers and
hoses.
4) Remove washer tank attaching bolts (4).
5) Remove washer tank (1).
6) Remove windshield washer pump (2) and rear
washer pump (3) from washer tank (1).
Installation
Install washer tank and washer pump by reversing
removal procedure, noting the following instructions.
• Connect washer pump connector(s) and hose
securely.
Washer Pump InspectionS6RW0D9406003
1) Connect battery positive (+) and negative (–)
terminals to pump (+) and (–) terminals respectively.
2) Check windshield and rear washer pumps for
operation.
If pump does not operate, replace washer pump.
Windshield Wiper Removal and InstallationS6RW0D9406004
Removal
1) Disconnect negative (–) cable at battery.
2) Remove wiper pivot caps (1) and wiper arm nuts (2),
and remove windshield wiper arms with wiper blades
(3).
3) Remove cowl top garnish referring to “Cowl Top and
Front Lower Crossmember Components in Section
9K”.
4) Disconnect coupler from windshield wiper motor.
5) Remove bolts (1), and remove windshield wiper
assembly (2).
5. Rear wiper arm with blade assembly 12. Wiper switch : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
6. Rear wiper motor 13. Rear wiper relay : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Washer pump for windshield washer 14. Junction block.
5. Right side headlight housing
1
4
34245
I7RW01940007-01
I5RW0A940004-01
1
3 3
2
I4RS0B940003-03
21I5RW0A940005-02